Method of forming multiple patterns



April 30,1946. R. J. MILLER METHOD OF FORMING MULTIPLE PATTERNS V Filed Nov. 11, 1 942 4 Sheets-Sheet 2 Y INVENTQR. Bar/401w! J/V/LLEE AVTOE/Vfi April 1946- R. J. MILLER 2,399,373

METfiOD OF FORMING MULTIPLE PATTERNS Filed Nov. 11, 1942 4 Sheets-Sheet s INVENTOR. Payne/v0 J/V/LLEE April 30, 1946; R. J. MILLER 2,399,373 METHOD OF FORMING MULTIPLE PATTERNS Filed Nov. 11, 1942 4 sheets-sheen:

will" INVEN TOR. Bar/valve JAY/4.452

Patented Apr. 30, 1946 Mernon or FORMING MULTIPLE m'r'rsans- Raymond J. Miller, Detroit, Mich.. asslgnor, by

direct and mesne assignments, to Miller Engineering Corporation, Detroit, Mich., a corporation of Michigan Application November 11, 1942, Serial No. 465,234

7 Claims.

This invention relates to patterns and more particularly to the making of multiple pattern equipment for use where a plurality of identical castings are to be formed in a single flask.

Heretotore three principal methods have been employed in the formation of multiple pattern equipment where a large number of castings are desired of a size such that a plurality of castings may be formed in a single flask. (1) The for mation of a plurality of castings from a master pattern embodying double shrinkage and finishing allowances. These castings are machined and hand iinished to embody the shape and contour of the desired article to be formed and include single shrinkage and finish allowances. (2) The machining and hand finishing from solid blocks of metal of a desired number of separate pattern segments conforming to the contour of the article to be formed and including single shrinkage and finish allowances. (3) The use of a number of master pattems secured to a gate, and these patterns and gate members used in a casting operation to form production pattern equipment.

These pattern segments are attached in any suitable manner to a plate to provide the desired multiple pattern equipment. In both these methods great diiiiculties have been encountered, particularly in the formation of patterns of articles of unsymmetrical contour where patterns oi vertically-spaced portions of the article to be cast must be provided to term cooperating mold impressions in the cope and drag sections of the dash.

The completed pattern segments must be accurately aligned vertically and in two dimensions horisontally on opposite sides of a single plate where a matched plate pattern is produced, or must be aligned accurately vertically and in two dimensions horizontally where the cooperating pattern segments are carried by separate plates to form the desired cooperating mold impressions. it the pattern segments are not properly aligned, the vertical edges of the mold ,cavities in the cope and drag sections of the flask will not align accurately and defective castings will result. In view oi these complications the cost and time required to make multiple pattern equipment has been undesirably high.

Because of. the human error involved in machining and hand finishing a large number of tions, it has been virtually impossible to form multipattern equipment of articles of complicated contours or shapes.

An object of this invention is to form multiple pattern equipment by a reproductive process from identical impressions of a single master pattern.

Another object of the invention resides in the provision of a novel method whereby multiple patterns may be quickly and accurately formed by a reproductive process from a master pattern.

A further object of the invention resides in the provision of an improved method whereby multiple pattern equipment, either of the matched plate or the single plate or dissociated type, may

be readily formed by a reproductive. process from a master pattern of any suitable material.

Still another object of the invention resides in the provision of an improved method of accurately locating cooperating pattern segments on opposite sides of a single plate where matched plate patterns are employed or on separate plates where simple plate patterns are used for casting purposes.

Another object is to provide a multiple patternforming mold having a plurality of spaced segments each having mold cavities formed from a master pattern by a reproductive process and bonded together in such a manner as to provide accurately located mold impressions.

Still a further object resides in the provision of an improved method of locating multiple pattern-forming mold cavities relative to each other by forming a plurality of blocks having impressions of a master pattern and locator means and positioning these blocks on correspondingly spaced locator means.

Yet another object is to provide multiple pattern equipment by a reproductive process from a lurality of accurately-spaced mold-impressions of a single master pattern.

A further object is to provide matched multiple pattern equipment formed by introducing into accurately spaced mold impressions of a master pattern a moldable substance capable of completely filling the mold impressions and accurately conforming to the contour thereof.

Still a further object of this inventionresides in the accurate positioning of a plurality of pattern impressions on a plate having locating means spaced correspondingly with locating impressions associated with the pattern impressions.

A further object resides in the provision of means for bonding together-a. plurality of pattern-impression-carrying blocks formed from a master pattern and accurately located on a plate to provide a female impression of multiple pattern equipment of a desired predetermined external size.

still another-object of this invention is to provide production multiple-pattern equipment formed by a reproductive process wherein impressions of locator means associated with a master pattern being reproduced are transferred to a plurality of mold impressions of the master pattern to accurately locate the mold impressions ona plate having locating means spaced correspondingly with the impressions of the locating means associated with the impressions of the master pattern.

Yet a further object is to provide multiple production pattern equipment including feeding runners by a reproduction process.

Another object of the invention is to form matched plate patterns by interposing a patterncarrying frame between vertically-spaced mold impressions of the article to be reproduced and filling the space within the frame and between the mold impressions with a moldable substance capable of filling and accurately conforming to the contour of th mold impressions.

A further object resides in the formation of multiple pattern equipment from identical female impressions of a pattern and locator means formed -by spraying molten alloy or metal directly onto the surface of the pattern and locator means.

Another object of the invention is to provide an improved method of forming multiple molds for making multiple wax patterns for use in the so-called disappearing wax method of casting.

Other objects and advantages of this invention will be apparent from the following detailed description considered in connection with the accompanying drawings, submitted for purposes of illustration only, and not intended to define the scope of the invention, reference being had for that purpose to the subjoined claims.

In the drawings wherein similar reference characters refer to similar parts throughout the several views:

Fig. 1 is a plan view of a split master pattern or model of any article to be reproduced.

Fig. 2 is an end elevation of the pattern illustrated in Fig. 1.

Fig. 3 is a side elevation thereof.

Fig. 4 illustrates the pattern equipment of Figs. 1 to 3 mounted on opposite sides of a patterncarrying plate.

Fig. 5 is an enlarged sectional view of the pattern illustrated in Fig. 4 showing a locator in place.

Fig. 6 is a plan view of the pattern equipment illustrated in Fig. 5.

Fig. '7 is a sectional view corresponding to Fig. 5 showing the formation of a block having an impression of the exposed portion of one of the pattern segments and of the locator.

Fig. 8 is a sectional view similar to Fig. 7 showing a modification of the method of forming a block having an impression of the pattern segment and locator means.

Fig. 9 illustrates the positioning of a plurality of pattern impression-carrying blocks on a plate provided with locating means spaced to correspond with the spacing of the locator means in the impression-carrying blocks.

Fig. 10 is a sectional view taken substantially on the staggered line Ill-l0 of Fig. 9 looking in the direction of the arrows.

Fig. 11 is a sectional view showing the bonding of the pattern impression-carrying blocks of Figs. 9 and 10 into a single pattern impression body.

Fig. 12 is a fragmentary sectional view similar to Fig. 11 showing the bonding together of the pattern impression-carrying blocks of Fig. 8 into a single pattern impression body.

Fig. 13 is a plan view of the multiple pattern impressions of Fig. 9 showing the gate and feederforming impressions.

Fig. 14 is a sectional view taken substantially on the staggered line l4-I4 of Fig. 13 looking in the direction of the arrows and showing the formation of the production multiple pattern equipment from the pattern impressions illustrated in Figs, 11 and 13.

Fig. 15 is a perspective View of a completed one-half of a production die pattern equipment.

Fig. 16 is a longitudinal sectional view showing several sets of production die patterns of Fig. 13 mounted in a flask.

Fig. 17 is a sectional view illustrating a modified form of the invention wherein multiple production pattern equipment is formed from a unitary master pattern and showing the step of embedding the pattern and locating means in any suitable parting material.

Fig. 18 is a sectional view illustrating the step of forming an impression of the exposed portion of the unitary pattern and locating means.

Fig. 19 is also a sectional view illustrating the step of removing the parting material and forming the reciprocal impression of the unitary pattern and locator members.

Fig. 20 is a fragmentary longitudinal sectional view illustrating the formation of matched plate production pattern equipment from vertically spaced mold impressions of the master pattern bonded together after having been located by means of locator pins.

Fig. 21 is a fragmentary sectional view illustrating the method of forming matched plate pattern equipment having a wide pattern parting plate.

Fig. 22 is a plan view of the embodiment illustrated in Fig. 21 and illustrating the step of aligning the pattern impressions with the pattern parting plate.

Fig. 23 is a perspective view of the completed matched plate production pattern equipment illustrated in Fig. 18.

Fig. 24 is a fragmentary sectional view illustrating the use of the multiple pattern impression molds in the formation of wax patterns for use in the so-called disappearing wax method of casting.

Before explaining in detail the present invention it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

Referring now to the drawings, Figs. 1 to 3 are illustrative of a master pattern 10 of any article which may be formed by a casting operation. The article to be cast need not be symmetrical, yet preferably but not necessarily embodies a straight parting line. example, be formed of wood or any other suitable substance and may be of the split type having cope and drag-sections l2 and M to form mold impressions in the cope and drag sections res e tively of a mold.

1Q, The article to be cast may, for example, be an The pattern In may, for.

- asoaszs' anchor-shaped article having spaced bosses ll and II interconnected by angularly-extending spaced rib members 2il. outwardly-directed projections 22 carried by the boss I! terminate in nukes 24. i

In the formation of multiple production pattern equipment from the master pattern II, the upper and lower sections l2 and i4 may be attached to opposite sides of a smalrplate 26 and accurately aligned with each other by means of pins 28 and 30 extending through holes drilled through aligned portions of the pattern segments i2 and it. At the time these holes are drilled the pattern segments should be accurately aligned with each other in order to locate them ac curately on opposite sides of the plate 28. The ends ofthe aligning and attaching pins 20 and it may be smoothed off with reference to the surface of the pattern members so as not to interferewith the contour of the article being reproduced.

ample they may be aligned and fastened to the plate by cementing, soldering, brazing, etc.

Apertures may be formed in the completed casting by providing kiss-through extensions in the mold-forming substance by providing apertures or cut-out portions in the cooperating pattern members. If apertures are desired in a casting Without the use of the kiss-through extensions in the mold-forming substance, the locating and attaching pins 2% and it may project through the apex-.-

ture-forming cutouts in the pattern members, and the pins 28 and 30 may be punch marked to reproduce on the casting a seat to locate'a drill.

In the use of my improved method of making multiple production pattern equipment, a pinrality of impressions of the cope and drag sections it and it of the pattern iii are formed in a substance possessing the characteristics of accurately conforming to the contour of the pattern and hardening or solidifying.

In view of the fact that the cope and drag sections t 2 and it of th pattern it are accurately aligned on opposite sides of the plate 26 by means of the pins 28 and 30, it is only necessary to provide locating means to accurately position the cope and drag pattern impressions with reference to each other to insure the formation of accurately aligned pattern impressions.

One desirable form of such locating means comprises locating pins 32 and 34 extending through the plate 26 and spaced from the pattern segments i2 and H. The distance between the locating pins may be chosen arbitrarily, but it is preferably an even dimension which may .be readily reproduced, as by locating the apertures in the plate by means of a template. The pins it and til are preferably tapered outwardly from a point adjacent the surface of the plate {26 to eliminate back draft and to facilitate the removal of moldable substance therefrom. I

Impressions of the cope and drag pattern seg ments and the cooperating locator means may then be formed in the moldable substance with assurance that when the cope and drag locator means are properly aligned with reference to each other, the impressions of the cope and drag pattern segments will be accurately aligned with each other.

After the cope and drag segments l2 and l4 of the pattern ill and locating pins 32 and 3| have thus been secured to the plate 28, a frame 30 may be positioned on the plate" to surround the upper segment I2 of the pattern it and the locating pins 32 and 34.

Moldable substance may then be introduced into the space within the frame 33 to form a block 38 having a female impression of the pattern segment i2 and the locating pins t2 and 84. After the block ti of the moldable substance has solidified or attained a predetermined set, the block 3t having the pattern and locating impressions therein may be removed from the plate iitand frame lit.

The moldable substance of which the block W is formed may be any substance capable of flowing and hardening under temperature and pressure conditions not injurious to the surface of the material of which the pattern it is formed and preferably embodying substantially constant volume upon change of state from liquid to solid.

Suitable materials for this purpose are 'the various woods or type metal, white metal, plaster of Paris, or dental plaster, the Cerro alloys such for example as cerrobend, an alloy possessing the characteristic of flowing at approximately and solidifying with negligible change of volume, and cerrobase, possessing the characteristic of flowing at approximately 350 F, being also desirable.

After a number of blocks it having female pattern and locating impressions therein correspending with the number of pattern members desired in the completed multiple pattern equipment have been formed, the plate it may be inverted. The frame fill may then be placed on the opposite side of the plate it to surround the drag pattern segment id, and theends of the 10- cating pins it and til project outwardly from that side of the plate it. A corresponding number of blocks having female impressions of the pattern segment it and locator pins 32 and lid may then be formed. If desired a plurality of frames dd may be employed and the blocks till may remain in the frames.

Fig. 8 illustrates a modified form of the invention wherein an impression of the pattern and locating means is formed in a block 3d of an alloy or metal. The block it is preferably formed by spraying any suitable alloy or metal onto the exposed surface of the pattern and locator members. The spraying operation is continued until approximately 1 6" of alloy or metal has been built up around the pattern and locator members and the exposed surface of the plate 2d. If de-' sired, a frame may be positioned around the pattern and locator members to confine the outer periphery of the block it, or the outer edges of the block dd may be cut away in any suitable manner to provide a block it having small marginal edges extending beyond the contour of the pattern and locator members. Where the block 39 is formed of a low melting temperature alloy it is desirable that the sprayed material be applied rather rapidly to prevent buckling.

A larger plate M is provided with apertures to receive a plurality of sets of locating pins M and M corresponding in contour and spacing to the pins 32 and 34 of the plate it. The locating pinreceiving apertures-may be accurately located in the plate MI by means of the same template plate used to locate the apertures for the locating pins 32 and 34 in the plate 26 on a jig borer may be employed to accurately locate the spacing of the apertures in the plate 40. The pins t2 and 44 proiect through the plate 43 and are preferably pf the same size and embody the same exposed tapered contour as the locating pins 32 and 34 positioned in the plate 23.

The frame 33 is preferably shaped to conform rather closely to the exposed contours of the cope and drag pattern segments l2 and I4 and the locator pins 32 and 34 employed in horizontally locating the spaced portions of the pattern l3 vertically relative to each other to permit the positioning of a large number of pattern-impression carrying blocks 33 or 39 on the larger plate 43. If the blocks 33 or 39 do not closely conform to the shape of the pattern and locating pins, the excess material of the blocks 33 disposed outside of the impressions of the pattern and locating members may be removed by any convenient cutting or machining operation.

The blocks 33 or 39 having the impressions of the pattern and locator means may be positioned on the plate43 with the pattern impressions directed towards the surface of the plate 43 and the locator pins 42 and 44 of the plate 43 projecting into the impressions of the locator pins 32 and 34 in the blocks 33 or 39.

In view of the fact that the blocks 33 or 39 have small marginal surfaces extending outside the contour of the pattern and locator means carried by the plate 23, the pattern impressions may be closely spaced on the plate 43, and a relatively large. number of identical pattern impressions may be positioned on the plate 43.

The locating pins 32 and 34 may be positioned closely adjacent to the contour of the pattern segments, since it is necessary only that they be spaced apart to accurately position thepattern impressions in a predetermined relation on the plate 40. If desired, a single locator member having a contoured surface such as an extended cylindrical member having a pointed side may be employed rather than the spaced pins 32 and 34. The individual pattern impressions of the multiple pattern equipment will therefore be closely spaced to assure economical use of the mold space in casting operations.

The plate 43 should preferably have an external dimension corresponding to that of a standard flask to permit the formation of multiple pattern equipment readily adaptable for use in molding operations.

Where special molding equipment is employed, such for example as in the Capaco process of plaster molding where a plurality of patterncarrying blocks of accurate external dimensions are fitted into a flask to form a die pattern, the plate 43 should preferabl accurately conform with the external dimensions of one of the pattern-carrying blocks.

In this process of molding, pattem-carrying blocks of a plurality of different sizes or of the same size may be.positioned adjacent each other in a flask to form plaster molds embodying mold impressions of aplurality of pattern members positioned in a single flask. Plates 43 of different external dimensions may be employed to form patterns conforming to any desired external dimensions usable in this or other methods of casting.

After the blocks 38 or 39 have been positioned on the plate 43 as illustrated in Figs. 9 and 10, the plate 43 may be positioned on a drag patternforming frame 53 to clear the pins 43 and 42 as illustrated in Figs. 11 and 12 respectively. Where the pattern equipment being formed is to be used in casting operations similar to the so-called Capaco process of plaster molding, the frame 33 is preferabl machined to accurate external dimensions corresponding with the dimensions of a pattern block for use in the Capace flask to form a die pattern. A cope pattern frame 32 of similar accurate external dimensions and contour is superimposed on the plate 43 to surround the blocks 33. The edges of the frame 32 and the plate 43 are then accurately aligned horizontally in two dimensions in a right-angle frame 34.

Any suitable moldable substance 33, such for example as Woods or type metal, white metal, plaster, or the Cerro alloys referred to above, or any suitable plastic material may be introduced into the space within the frame 52 to engage and securely lock the blocks 33 or 39 together and to the frame 32. The inwardly-extending head 33 carried by the frame 32 projects into the substance 53 to securely bond the substance 33 and the blocks 33 or 39 to the frame 52 to form a female multiple pattern impression 63.

One of the female multiple impressions 33 or 32 ma be cut away or contoured to provide an impression of a main feeding conduit 13, including impressions of branch conduits 18, leading to each of the pattern impressions of the article to be cast. Impressions of a surge pool 33 and a riser 32 communicating with the feeding conduit 13 may also be formed in the female multiple impression.

It will be apparent that, if desired, a gate tree having main and branch conduit impressions l3 and 13 and impressions of the surge pool 33 and riser 32 maybe positioned on the plate 43 to communicate with the pattern impressions in the blocks 33 or 39 in the step illustrated in Figs. 9 and 10 before the substance 53 is applied in the step illustrated in Figs. 11 and 12 to' securely bond the pattern impression-carrying blocks 33 or 39 together.

After the substance 56 has solidified or hardened, the frames 53 and 52 with the plate 43 interposed between them may be inverted. The blocks of moldable substance having the impressions of the drag pattern segments I4 and the locator means may then be applied to the exposed surface of the plate 43 within the drag patternforming frame 53, the impressions of the locator pins 32 and 34 fitting over the locating pins 42 and 44 of the plate 43 to accurately locate the drag pattern impressions relative to the cope pattern impressions vertically and in two horizontal dimensions. The frame 53 and the plate 43 should again be accurately aligned in the rightangle 54 and the blocks having the impressions of the drag pattern segments i4 bonded together and to the frame 53 in the manner previously indicated to form a female multiple impression 62 of the drag pattern segments l4 and locator means, illustrated in Fig. 18 and corresponding with the female multiple impression 33,

The female multiple cope and drag impressions 63 and 32 thus formed may be separated from the plate 43 and used, as illustrated in Fig. 14, to form production pattern equipment having impressions for the runner and feeder members.

The impressions of the locator means 32 and 34 formed in the blocks of the cope and drag female multiple impressions 63 and 62 may be filled before the production pattern equipment is formed as illustrated in'Fig. 12. Any suitable substance may be employed for this purpose such for example as smooth-on, a metal compound, emery powder, plaster, or any of the Cerro alloys. It is desirable that a point of anchorage be provided to prevent the closure plugs from coming out of the apertures. This may be accomplished by\ running a. drill hole in the walls of the apertures. Where the Cerro alloys are employed to fill the locating pin apertures, the hole may be poured full and a flat iron bar may be moved across the top of the aperture to level off the applied substance and to cause it to chill.

Where the pattern equipment is to be used in the so-called Capaco process of plaster molding a pattern-carrying frame 88 having accurate external horizontal and vertical dimensions conforming with the required dimensions of the pattern-carrying blocks of a die pattern is super-- imposed on the frame 52 and is accurately aligned therewith in two dimensions horizontally by means of the right angle 54. The frame 68 may be provided with internally threaded bosses ti to facilitate attaching the pattern block to the flash to form a die pattern. A riser frame to conforming with the requiredhorizontal dimensions of the pattern-carrying block is superimposed on the pattern-carrying frame 68 and is aligned therewith by means of the right angle til. It will be obvious that a number of die patterns can be made from the same female impression. The use of the riser frame fit in the making of production pattern equipment is more fully disclosed in my copending application Serial No. teaser, filed August 1d, 1942.

When the frames 52 and 68 have been properly aligned, a pattern-forming moldable substance it is introduced into the space within the frames tt and tt to fill the impressions of the pattern segments it in the female multiple impression till and to form a multiple production pattern ill having a plurality of spaced pattern segments it accurately conforming with the shape and contour of the pattern segment is as illustrated in Fig, 15. Production pattern equipment accurately conforming to the shapeand contour of the pattern segment i4 may be formed in a similar manner from the female multiple impression We.

The pattern-forming moldable substance may be any suitable alloy or metal such for example as alloys of the Woods metal group, type metal, white metal, the Cerro alloys including cerrobend, cerrobase, cerromatrix, etc.. or any suitable plastic material of the thermoplastic or thermosetting type.

To summarize the steps of accurately forming the cope and drag production pattern equipment it will be noted that the pattern segments it and it are accurately located relative to each other by the pins 28 and 30 extending through the plate 26. The impressions of these spaced pattern'segments are accurately located relative to each other on their respective impressioncarrying blocks by the impressions of the locatorv pins t2 and M projecting through the plate 28.

When the pattern impression-carrying blocks are mounted on the plate 40, the impressions of the pattern segments 12 and It are accurately located relative to each other in two dimensions horizontally by the locating pins 42 and M in the plate M] and the pattern impressions are accurately located vertically by contact of the base of the impression-carrying blocks with the surface of the plate 40.

The impression-carrying blocks are accurately located relative to each other by alignment of the frames 52 and lit with the edges of the plate '40 by means of the right angle 54, and'the impressicn-carrying blocks are then bonded together and to their respective frames as illustrated in Figs. 11 and 12.

The pattern segments 14 of the production pattern equipment 12 are accurately located with reference to the edges of the frame 66 because of the alignment of the edges of the frame at with the edges of the frame 62 as illustrated in Fig. 14. The pattern segments of the production pattern equipment of the pattern segments it are correspondingly accurately aligned with reference to the edges of their corresponding frame or pattern plate. Assurance is thus had that the pattern segments of the cooperating pattern equipment will accurately align with each other to form accurately aligned mold impressions to produce good castings.

Where this pattern equipment is to be used in the so-called Capaco process of plaster molding, the production pattern i2 thus formed may be positioned in a flash to as illustrated in Fig. 16 to form a die pattern for the reception of a plaster molding substance to form cooperating cope and drag mold sections having impressions of the pattern segments it and it respectively for use in casting operations.

After the plaster or other mold-forming sub-' stance has attained a predetermined set in the flaslr M, the mold is'extracted from the pattern, and the mold is subjected to drying and curing operations whereby virtually all the moisture is dispelled from the mold to provide cooperating mold members having smooth, highly calendered surfaces accurately conforming to the contour of. the pattern impressions. Molten alloy or metal may be poured directly into these mold impressions to form the desired castings. Due to the smooth, highly glazed surfaces of the mold impressions, castings having smooth surfaces accurately conforming to the contour of the pattern result, and in the majority of instances the castings may be used directly for industrial purposes without the necessity of additional machining operations.

Figs. 1 to l5 illustrate the formation of multiple production pattern equipment from split patterns wherein upper and lower sections l2 and it of the pattern equipment it are positioned on opposite sides of the plate 26, as in matched plate pattern practice. Figs. 17 to 19 illustrate the steps necessary in the formation of multiple production pattern equipment from a unitary pattern member at.

The unitary pattern fit is embedded in any suitable parting material W to a point 9 3 conforming to the natural parting line on the pattern. The parting material 92 may be any substance suitable for forming partings, such for example as molding clay, dental plaster, waxes of various types, plaster of Paris, et cetera. After the pattern has been embedded in the parting material 92 to the desired level, suitable locating means such as two locating pin t8 corresponding with the locating pins 32 and it illustrated in Figs. 5 to 7 are also embedded in the parting material 92. The locating pin at taper in opposite directions from a point 98 approximately midway of their length. The pins 96 are embedded in the parting material 92 up to the point 93 to eliminate back draft in the portions of the pins 9% embedded in the parting material and the exposed portions thereof.

After the pattern member 9t and the locating pins 96 have been embedded in the parting I to surround the pattern member and the locating pins. Any suitable moldable substance I02 may then be introduced into the space within the frame I to form a block having a female impression of the exposed portion of the pattern member 90, locating pins 98, and the parting material 92. These blocks corresponding with the block 38 or 39 formed in the step illustrated in Figs. 7 and 8 may be removed from the pattern and pattern and locating members 90 and 96 upon hardening or solidifying and used in the steps illustrated in Figs. 9 to 11 in the formation of multiple female impressions 60, each accurately conforming with "the contour of the exposed portion of the pattern member 90 and locating members 96'.

After a desired number of blocks having the desired pattern and locator impressions have been formed, they may be used, as illustrated in Figs. 9 to 14, in the formation of the desired production pattern equipment. One additional impression of the exposed portion of the pattern and locator means is formed, and the pattern is inverted as illustrated in Fig. 19 to rest on the frame I00. The parting material 92 applied in the step illustrated in Fig. 17 i then removed, and a frame I04 is superimposed on the frame I00. Moldable substance I06 is then introduced into the space within the frame I04 to form blocks having female impressions of the exposed portion of the pattern member 90, locating means 96, and the surface of the block I02 formed in the step illustrated in Fig. 18. Accurately matched impressions of vertically-spaced portions of the pattern member and locator means are thusformed from the unitary pattern memher for use in making the desired production pattern equipment.

The multiple female impressions 60 and 62 formed in the steps illustrated in Figs. 1 to and 15 to 17 may be used'in the formation of matched plate pattern equipment.

As illustrated in Fig. the plate 40 illustrated in Fig. 11 may be replaced by a frame IIO after the impression-carrying block have been bonded together as illustrated in Figs. 11 and 12. The frames 50 and 52 may be accurately aligned in two dimensions horizontally with the edges of the plate I I0 by means of the right angle 54 as illustrated in Fig. 20. A feeding aperture H2 may be provided to supply molten alloy or metal to the space within the frame 0 and the pattern impression carried by the multiple female impression 60 and 62 to form a matched plate pattern having accurately-spaced pattern segments on opposite sides thereof as illustrated in Fig. 23.

If a matched plate pattern having a wide pattern plate is desired, the frame I I0 of Fig. 20 may be dispensed with and a wide pattern frame I20 applied as illustrated in Figs. 21 and 22. The pattern plate I 20 may be provided with a plurality of pins I22 as illustrated in Figs, 21 and 22 against which the edges of the frames 50 and 52 may abut to accurately align the female impressions in the multiple female members 60 and 62 horizontally in two directions with reference to each other and to the plate I20. The impressions of the cope and drag pattern members in the female multiple impressions 60 and 62 respectively are thusaccurately aligned to form cope and drag pattern segments disposed on opposite sides of the plate I 20. It will be apparent that the material of which the pattern is formed completely fills the space within the frame and between the pattern impressions. This material engages on opposite sides of the contoured section I24 of the frame I20 to securely bond the pattern material to the frame I 20.

If more durable or stronger pattern equipment is required than is afforded by the moldable substance I0 employed in the formation of production patterns, the multiple pattern equipment thus formed may be used as an intermediate step in the formation of production patterns of brass, bronze, aluminum, or any suitable high-strength alloy. When this expedient is resorted to the master pattern or model'should embody double shrinkage allowance.

The multiple production pattern I2 formed by the reproductive process set out above may be employed in the so-called Capaco method of plaster molding to form production pattern equipment of suitable alloys or substances. In view of the accuracy of casting operations by the socalled Capaco process, it is only necessary that approximately .002" be provided for finishing the production high-strength pattern equipment.

The multiple production pattern equipment 12 or the multiple match plate pattern of Figs. 20 to 23 may also be used in the formation of dies for plastic molding operations where great hardness is required. Alloys such for example as Beryllium copper having a hardness factor in excess of 387 Brinell are now available for use in this manner.

The female multiple pattern-forming molds 80 and 62 may be assembled as illustrated in Fig. 24 and used in the formation of wax patterns for use in the so-called disappearing wax method of forming castings. Where the multiple molds 80 and 62 are used in this manner, a locator member such for example as a dowel pin I30 may be employed at each end to locate the mold members 80 and 02 relative to each other. The dowel pins I30 may be located in position at the time the substance 66 is applied to bond together the impression-carrying. blocks 38 or 39. Main and branchfeedlng conduits I32 and I34 respectivel may be provided to admit the wax to the pattern molds to form the desired multiple wax patterns.

Plastic materials either of the thermoplastic or thermosetting types may be employed in the formation of the blocks carrying the female impressions or in the formation of the production pattern equipment desired.

I claim:

1. I'he method of making multiple production patterns comprising securing a master pattern to a plate, positioning locating pins on the plate, forming a plurality of separate blocks each having a female impression of the pattern and recesses for the locating pins, providing a larger plate with a plurality of sets of locating pins, 10- cating a plurality of blocks on the larger plate and aligning the recesses with the locating pins, bonding the separate blocks together to form a multiple pattern mold, and forming a production pattern from the multiple pattern mold.

2. The method of forming multiple pattern equipment from a master split pattern comprising aligning the cope and drag pattern segments on opposite sides of a plate and attaching them thereto, projecting aligning means through the plate adjacent the pattern segments, forming a plurality of blocks having impressions of the cope and drag pattern segments and aligning means,

positioning a plurality of said blocks on opposite 9 sides of a larger plate having similar aligning means to accurately locate the impressions of the aeeas cope and drag pattern segments on opposite sides of the larger plate, positioning frames around the blocks having the impressions of the cope and drag pattern segments, aligning the edges of the frames and plate, bonding said blocks to their equipment from a unitary master pattern comprising embedding said pattern in parting material to divide the pattern into cope and drag sections and to eliminate back draft, embedding aligning means in the parting material adjacent the pattern and to eliminate back draft, forming a plurality of blocks having impressions of the cope and drag pattern sections and aligning means, positioning a plurality of said blocks on opposite sides of a larger plate having similar aligning means to accurately locate the impressions of the cope and drag pattern segments on opposite sides of the larger plate, positioning frames around the blocks having the impressions of the cope and drag pattern, aligning the edges of the frames and plate, bonding said blocks to their respective frames to form multiple female impressions of the cope and drag pattern segments, and forming multiple cope and drag patterns from the cope and drag multiple female impressions.

4. The method of forming molds for making multiple production patterns comprising securing master pattern segments on opposite sides of a plate, positioning locating means adjacent the pattern segments, forming a. plurality of separate blocks each having a female impression of a pattern segment and an impression of the locating means, providing a larger plate with a plurality of locating means, locating a plurality of blocks on the larger plate and aligning the impressions of the locating means on the locat-.

ing means of the larger plate, and bonding the separate blocks together to form a multiple pattern mold.

5. The method of making match plate production pattern equipment comprising forming mold blocks having impressions of vertically-spaced portions of a master pattern and impressions of spaced locator members, locating impressions of vertically-spaced pattern portions in spaced alignment by aligning impressions of locator members with similarly positioned locator members carried by a flat plate, bonding the blocks together on the fiat plate to form molds having a plurality of female impressions of the master pattern, and forming production match plate pattern equipment from the molds having said multiple female impressions.

6. The method of forming matching cope and drag multiple production patterns comprising forming a plurality of blocks having female impressions of spaced portions of a master pattern and impressions of spaced locator means, positioning said blocks on a plate having locator means with the impressions of the locator means in the blocks on the locator means of the plate to locate the cope and drag mold cavities of the blocks inspaced alignment, bonding said blocks together to form cope and drag molds each having a plurality of identical impressions of the spaced portions of the master pattern, and forming production patterns from said molds.

7. The method of making a matched plate multiple pattern from a unitary master pattern, comprising forming a plurality of blocks having cope and drag impressions of spaced portions of the master pattern and impressions of spaced locator means, successively positioning the cope and drag impressions of spaced portions of the pattern on opposite sides of a plate having similarly spaced locator means projecting therethrough to locate the cope and drag impressions of the pat- I tern relative to each other, bonding the impression-carrying blocks together to form cope and drag molds each having a plurality of aligned female impressions of the, spaced portions of the 'master pattern, positioning a frame between the cope and drag molds, and forming the matched plate multiple pattern by introducing a moldable substance into said pattern impressions and frame.

RAYMOND J. MILLER. 

